Modular electrical device

ABSTRACT

A modular base for an electrical device and an electrical device including same and also removable modules are disclosed. The modular base comprises a plurality of base components adapted to be arranged relative to each other to define a backplane comprising a plurality of module mounting locations, wherein each mounting location comprises a first electrical base connector of one base component and a second electrical base connector of another base component. A plurality of removable modules are adapted to be respectively removably connected to the backplane in the mounting locations to provide a modular electrical device. Each of the modules comprises a first module connector adapted to be mated with a first base connector of a mounting location and a second module connector adapted to be mated with a second base connector of the mounting location The backplane comprises one or more coupling devices for releasably engaging a module.

BACKGROUND

The present development relates to a modular electrical device and, moreparticularly, to a modular electrical device that is highly resistant toingress of water, oil, debris, dirt and other contaminants encounteredin manufacturing and other environments without use of a separateenclosure. As described herein, one application for a device formed inaccordance with the present development is as a modular distributedinput/output (I/O) assembly that forms a part of or is connected to anindustrial automation control system. Those of ordinary skill in the artwill recognize that the device has other applications, and it is notintended that the device be limited to use for any particularapplication.

In connection with industrial automation control systems and otherelectrical systems, it has been deemed desirable to provide electricaldevices for transmission/input/output of data signals and/or powervoltages that are distributed throughout a manufacturing, distributionor other facility and located directly on or adjacent machinesperforming manufacturing, distribution, inspection and/or otherprocesses. It has also been found that, in certain cases, theseelectrical devices should be modular to allow for customization,re-configuration and repair/replacement as needed during installation orlater. This modularity improves usability but can lead to ingress ofwater, oil, dirt, debris, and/or other contaminants into the device,with highly undesirable consequences. Furthermore, modular componentscan undesirably separate owing to vibration, impact, cable stresses orother external forces.

Certain modular electrical devices are housed within an enclosure thatprovides secure mounting and also protects the device from environmentalcontamination. Use of an enclosure is often not practicable due to spaceconstraints, ease of installation/re-configuration/repair and/or otherconcerns.

Contamination-resistant modular electrical devices are known. Oneexample is a distributed input/output (I/O) assembly availablecommercially from Rockwell Automation under the trademark 1798 FLEXArmor™. I/O circuitry is packaged in I/O modules, and the I/O modules ofan assembly plug into a common baseplate. The baseplates is available insizes of 2, 4, 6, and 8 I/O module slots. An I/O adapter module and afield termination module plug into two slots of the baseplate. Thebaseplate holds the modules in place and provides the backplane for theassembly. No enclosure is required because each module is packaged in asealed housing rated for IP65/67 and NEMA 4× (indoor/outdoor) and 6 P.While the FLEX Armor™ I/O system has enjoyed widespread commercialsuccess, certain modifications have been deemed desirable, at least forparticular applications. For example, with the FLEX Armor™ system, thebaseplates are available in units of 2, 4, 6 and 8 I/O modules. Also, tomaintain the environmental ratings, all slots on the baseplate must befilled with either a live I/O module or a filler module.

Other modular electrical devices that are resistant to environmentalcontamination are known and available commercially from other sources.Some of these devices rely on conventional O-ring seals or other typesof seals that provide only a single sealing dynamic at each sealinglocation, i.e., only radial/lateral sealing or only axial/compressivesealing. In certain cases, these seals are susceptible to leakage,especially when the modular components are subjected to vibration orother external forces such as lateral and/or axial separation forces.Other known devices utilize conventional O-rings seals or other sealsthat are positioned in a manner where they can be damaged or dislodgedduring handling, installation or during repair/replacement operations.Another drawback associated with some of these conventional modularelectrical devices is that the seal is connected to or forms a part ofthe permanent components of the system, instead of the replaceablecomponents. As such, use of a replacement component does notautomatically result in use of a new seal. Known modular electricaldevices have also been found to be sub-optimal insofar as operativemating of the components is concerned. Some require use of separatefasteners such as screws or the like which can be inconvenient and canlead to component damage if the fasteners are over-torqued. Othersystems rely on a simple friction fit between components, and this canlead to unintended separation of the components such as when thecomponents are mounted in an inverted position and/or in response tocable strain. Known systems have also not provided base components thatare conveniently and securely mechanically with each other to ensureproper definition of the module mounting locations and to minimizeundesired movement between base components. Examples of known modularelectrical devices can be found in the following documents: U.S. Pat.No. 6,475,036; U.S. patent application Publication No. 2002/0182942;U.S. Pat. No. 4,707,043; German Utility Model No. DE29703367U1; and,German Utility Model No. DE29607525U1.

In light of the foregoing, it has been deemed desirable to provide a newand improved modular base for an electrical device, and/or an electricaldevice including the modular base and removable modules with improvedoperative mating of components so as to facilitate use and improveingress protection.

SUMMARY

In accordance with one aspect of the present development, a modularelectrical device comprises a modular base comprising a plurality ofbase components adapted to be arranged relative to each other so as todefine a backplane comprising at least one module mounting location,wherein the at least one mounting location comprises a first electricalbase connector of one base component and a second electrical baseconnector of another base component. At least one removable module isadapted to be respectively removably connected to the backplane in theat least one mounting location. The module comprises: (i) a first moduleconnector adapted to be mated with the first electrical base connectorto form a mated pair of first connectors; and, (ii) a second moduleconnector adapted to be mated with the second electrical base connectorto form a mated pair of second connectors. The module is adapted toelectrically interconnect said first and second electrical baseconnectors of the mounting location. A coupling device is connected tothe backplane and is located in the mounting location. The couplingdevice is adapted to releasably secure the module to the backplane.

In accordance with another aspect of the present development, a modularbase for an electrical device comprises at least two separate basecomponents adapted for selective mechanical mating via correspondingmale and female portions so as to define a backplane that comprises atleast one module mounting location. Each of the at least two basecomponents comprises at least one electrical connector. The at least onemounting location comprises first and second electrical connectors thatform a part of respective first and second ones of said at least twobase components.

BRIEF DESCRIPTION OF THE DRAWINGS

The development comprises components and arrangements of components,preferred embodiments of which are disclosed herein and shown in thedrawings that form a part hereof, wherein:

FIG. 1 is an isometric view of a modular electrical device formed inaccordance with the present development;

FIG. 2 is similar to FIG. 1, with all removable modules thereof notshown to reveal the underlying base assembly;

FIGS. 3, 4 and 5 are isometric views of an adapter base component, anintermediate base component, and an end base component, respectively;

FIGS. 6, 7 and 8 are top plan, bottom plan and isometric views,respectively, of one example of a removable module component formed inaccordance with the present development;

FIG. 9 is a sectional view as taken along line 9-9 of FIG. 6;

FIG. 10 is a side view showing a removable module separated from aportion of the base assembly to which it is adapted to be operativelymated;

FIG. 11 is an isometric view that shows the removable module and portionof the base assembly of FIG. 10;

FIG. 12 is similar to FIG. 4, but shows the intermediate base componentwith an upper surface thereof partially removed to reveal a couplingdevice formed in accordance with the present development;

FIG. 13 is a bottom plan view of the intermediate base component shownin FIG. 12;

FIG. 14 is a side view of a removable module mated with the couplingdevice of an intermediate or end base component, with portions in theforeground not shown and portions of the base component broken away forclarity;

FIG. 15 is an isometric view of a sliding lock member component thatforms a part of the coupling device;

FIGS. 16A and 16B diagrammatically illustrate use of the coupling deviceto eject a removable module in accordance with the present invention;

FIG. 17A is an isometric view of the inner housing portion of aremovable module;

FIG. 17B is a sectional view as taken along line B-B of FIG. 17A;

FIG. 17C is similar to FIG. 17B but shows an isometric sectional view;

FIG. 18A is a top plan view of an alternative seal formed in accordancewith the present development as operatively mounted to a base component;

FIG. 18B is a sectional view as taken along line B-B of FIG. 18A; and,

FIGS. 19A and 19B show a modular electrical device formed in accordancewith an alternative embodiment of the present development.

DETAILED DESCRIPTION

FIG. 1 illustrates a modular electrical device 10 in accordance with thepresent development. The device 10 comprises a modular base assembly 12and one or more removable modules 14. The modules 14 are releasablyconnected to the base assembly 12 and can be selectively removed toreveal the underlying base assembly 12 as shown in FIG. 2. The device 10can be electrically configured to perform any of a wide variety offunctions, and it is not intended that the development as describedherein be limited to any particular electrical function. For ease ofexplaining the development 10, however, reference is made herein to useof the device 10 as a distributed modular input/output (I/O) assembly asused, e.g., as part of an industrial automation control system.

FIG. 2 shows that the base assembly 12 comprises a plurality of modularbase components 12 c (i.e., more than one) arranged adjacent each other,preferably mechanically interconnected with each other, so as to definea field bus or backplane 20. The backplane 20 defines a plurality ofmodule mounting locations such as the four mounting locations M1-M4shown in FIG. 2. As is described in full detail below, each mountinglocation is adapted to receive and releasably retain one of theremovable modules 14.

In a typical installation, the base assembly 12 is defined by a singleadapter base component 12 c 1, one or more intermediate base components12 c 2 and a single end base component 12 c 3. The number ofintermediate base components 12 c 2 is varied to control the number ofmounting locations M1-M4 defined by the backplane 20.

An adapter base component 12 c 1 is shown separately in FIG. 3 andcomprises a body 30 to which network (e.g., data/power) connectors 30 aare affixed. The network connectors 30 a are conventional and provideinput and/or output of electrical power and data to/from an externalnetwork. The adapter base component 12 c 1 further comprises a firstbase connector 30 b 1 including one or more contacts 30 c which cancomprise, e.g., male or female contacts. The base connector 30 b 1 isshown as a male plug connector with female contacts 30 c, but could alsobe a female socket connector with male pin contacts. The networkconnectors 30 a and contacts 30 c are electrically connected toelectronic circuitry 30 d housed within the body 30 as shown by paths 30p. LED's or other visual output devices 30 e are connected to and/orform part of the circuitry and provide visual output on the status ofthe circuitry 30 d.

The network connectors 30 a provide for input and output of power and/ordata between the circuitry 30 d and other portions of the modularelectrical device 10 and an external network, as controlled by theelectronic circuitry 30 d, while the first base connector 30 b 1 andcontacts 30 c thereof provide for input and output of data and/or powerbetween the adapter base component 12 c 1 and other portions of thedevice 10, such as the intermediate base component(s) 12 c 2 and endbase component 12 c 3 of the base assembly 12, and the removable modules14 connected thereto. In one example, the modular electrical device 10is provided as a distributed I/O assembly for an industrial automationnetwork, and the network connectors 30 a and circuitry 30 d areconfigured to connect and communicate with the external automationnetwork. The electronic circuitry 30 d and, except for the accessiblemating portions, the network connectors 30 a and contacts 30 c, aresealed within the body by potting compound or other means to protectagainst environmental contamination.

The body 30 of the adapter base component 12 c 1 comprises a firstpuzzle-piece connector structure P1 defined by a first peripheral edge30 e 1. The first puzzle-piece connector structure P1 comprises one ormore male projections P1 a and female recesses P1 b. The first baseconnector 30 b 1 is located on one of the male projections P1 a.

FIG. 4 illustrates an intermediate base component 12 c 2. Theintermediate base component comprises a body 32 which includes bothfirst and second base connectors 30 b 1,30 b 2 each including one ormore contacts 30 c which can comprise, e.g., male or female contacts.The base connectors 30 b 1,30 b 2 can be male (plug) connectors (asshown) or female (socket) connectors. Each contact 30 c of the firstbase connector 30 b 1 is electrically coupled to a corresponding contact30 c of the second base connector 30 b 2 by conductor bars 32 d or thelike which are sealed in the body 32 by potting compound or other means.

The body 32 of component 12 c 2 comprises a first peripheral edge 32 e 1that also defines the first puzzle-piece connector structure P1described above. The body 32 further comprises a second peripheral edge32 e 2, located opposite the first peripheral edge, that defines asecond puzzle-piece connector structure P2 that includes one or moremale projections P2 a and female recesses P2 b that are conformed tomate closely with corresponding male/female structures P1 a,P1 b of thefirst puzzle-piece structure P1 in only a single possible position. Assuch, the second puzzle-piece structure P2 of an intermediate basecomponent 12 c 2 is mated with the first puzzle-piece structure P1 ofthe adapter base component 12 c 1 or another intermediate base component12 c 2 as shown in FIG. 2.

FIG. 5 illustrates an end base component 12 c 3. The end base componentcomprises a body 34 which includes only a second base connector 30 b 2having one or more contacts 30 c which can comprise, e.g., male orfemale contacts. The base connector 30 b 2 can be male (plug) connector(as shown) or female (socket) connector. In certain cases, the contacts30 c of the end base module 12 c 3 can be non-functional (e.g., groundedthrough one or more resistors or otherwise) because they are located atthe terminal end of the backplane 20.

The body 34 comprises a first peripheral edge 34 e 1 that isnon-functional and further comprises a second peripheral edge 32 e 2,located opposite the first peripheral edge, that defines the secondpuzzle-piece connector structure P2 as described above, including theone or more male projections P2 a and female recesses P2 b that areconformed to mate precisely and in only one possible position withcorresponding male/female structures P1 a,P1 b of the first puzzle-piecestructure P1. As such, the second puzzle-piece structure P2 of the endbase component 12 c 3 is mated with the first puzzle-piece structure P1of the adapter base component 12 c 1 or an intermediate base component12 c 2 as shown in FIG. 2.

Referring again to FIG. 2, it can be seen that when the backplane 20 isconstructed by the adapter base component 12 c 1, at least oneintermediate base component 12 c 2 and an end base component 12 c 3, themounting locations M1-M4 each comprises a corresponding pair of baseconnectors 30 b 1,30 b 2, i.e., a first base connector 30 b 1 from afirst base component 12 c and a second base connector 30 b 2 from asecond, adjacent base component 12 c. The backplane 20 can alternativelycomprise only the adapter base component 12 c 1 and the end basecomponent 12 c 3 so as to comprise only a single mounting location.Corresponding pairs of base connectors 30 b 1,30 b 2 defining eachmounting location M1-M4 are electrically connected only through theremovable modules 14, when the modules are mated to the backplane 20.The various mating puzzle-piece structures P1,P2 mechanicallyinterconnect the base components 12 c 1,12 c 2,12 c 3, and ensure properspacing and alignment of the corresponding pairs of base connectors 30 b1,30 b 2 to define the mounting locations M1-M4 to allow for releasablemating of a module 14. Each base component 12 c 1,12 c 2,12 c 3 includesat least one aperture or other fastener-receiving location 12 f adaptedto receive a screw, rivet, clip, pin or other fastener or fasteningmeans for fixedly securing the base component 12 c 1,12 c 2,12 c 3 to asupport surface.

With reference again to FIG. 2, the base connectors 30 b 1,30 b 2include outer surfaces 36 b 1,36 b 2 and transverse end walls 38 b 1,38b 2, respectively. As shown, the base connectors 30 b 1,30 b 2 arefrusto-conical in shape, with the outer surfaces 36 b 1,36 b 2converging slightly (e.g., at a 1 degree angle) moving toward thetransverse end walls 38 b 1,38 b 2, but the outer surfaces 36 b 1,36 b 2can also be purely cylindrical or otherwise shaped. The frusto-conicalshape is thought to facilitate sealing and unsealing between theconnectors 30 b 1,30 b 1 and a module 14 mated therewith as describedbelow. The end walls 38 b 1,38 b 2 define apertures 39, and the contacts30 c are located within these apertures (for female contacts as shown)or project through these apertures (for male contacts).

FIGS. 6-9 illustrate one example of a removable module 14 formed inaccordance with the present development. Each module 14 comprises ahousing 40 constructed from inner and outer housing members 40 a,40 bthat are inter-fitted with each other to define an enclosed interiorspace 42 (FIG. 9) in which electronic circuitry 44 is located.

A plurality of connectors 46 are operably connected to the circuitry 44and project through the outer housing member 40 b so as to be adaptedfor mating with corresponding cable connectors from external devices.The circuitry and connectors 44,46 are adapted for any desiredelectrical application. In one example, each module 14 performs as anindustrial automation I/O module to which field devices and the like areconnected via connectors 46, and the circuitry 44 is configured for thispurpose. FIG. 1 shows a plurality of differently configured removablemodules 14 including different types and arrangements of circuitry 44and connectors 46. Regardless of the configuration, modules 14 typicallycomprises a visual indicators such as LED's 48 a that provide visualoutput signals concerning the state of the circuitry 44 and markerholders 48 b used for labeling connectors 46 or for other purposes.

The housing 40 is sealed against ingress of environmental contaminants.The circuitry 44 and connectors 46 are potted within the outer housingmember 40 b or otherwise sealed in place. The inner housing member 40 ais then sealed within the outer housing member, preferably by bothmechanical and adhesive means, to provide the sealed interior space 42.With reference to the sectional view of FIG. 9, it can be seen that theinner housing member 40 a is adapted for nesting within the outerhousing member 40 b and comprises a plurality of tabs 50 a that arereceived in corresponding recesses 50 b such as notches, or aperturesdefined by the outer housing member 40 b so that the housing members 40a,40 b are mechanically interlocked with a close snap-fit. The tabs 50 acan alternatively project from the outer housing 40 b and the recesses50 b can be defined in the inner housing 40 a. Furthermore, the innerhousing member 40 a comprises a continuous wall 52 a projectingoutwardly therefrom that is received within a corresponding continuouslyextending groove 52 b defined by the outer housing member 40 b. Thejoint at the junction of the wall 52 a and groove 52 b is sealed with agasket or, preferably, with an adhesive and/or sealant such as, e.g.,epoxy.

The housings 30,32,34 of the base components 12 c 1,12 c 2,12 c 3 andthe inner and outer housing members 40 a,40 b of the removable modules14 are preferably defined as molded polymeric constructions utilizingany of a wide variety of polymeric materials in an injection moldingprocess. One suitable material is glass-filled polyester, although it isnot intended that the development be limited to such material or anyother material.

As noted above, each module 14 is adapted for releasable connection tothe backplane 20 of the base assembly 12. To this end, each releasablemodule 14 comprises first and second module connectors 60 b 1,60 b 2(see e.g., FIGS. 7,8) that are adapted to mate respectively with acorresponding pair of first and second base connectors 30 b 1,30 b 2 ofthe backplane 20 at each mounting location M1-M4. In the illustratedembodiment, the first and second module connectors 60 b 1,60 b 2 arefemale or socket connectors comprising a plurality of male (as shown) orfemale contacts 60 c, wherein the contacts 60 c are electrically coupledto the module circuitry 44 and/or to other contacts 60 c by paths 44 pas shown in FIG. 7. Each base connector 60 b 1,60 b 2 is dimensioned andconformed for mating with a base connector 30 b 1,30 b 2 of thebackplane 20, so that the contacts 60 c mate with corresponding contacts30 c of the base connectors 30 b 1,30 b 2 to establish electricalconnection between the backplane 20 and the modules 14. In this manner,the modules 14 act as and provide electrical links by which theindividual base components 12 c are electrically interconnected to eachother through their base connectors 30 b 1,30 b 2 so that data and/orpower can flow from each module 14 to each other module 14, from eachbase component 12 c to each other base component 12 c, and/or from eachmodule 14 to each base component 12 c, including the adapter basecomponent 12 c 1 and circuitry 30 d thereof as required for use of thedevice 10.

FIGS. 10 and 11 are provided to show the relationship of a removablemodule 14 to the backplane 20 of base components 12 c as the removablemodule is about to be connected to the backplane. There, it can be seenthat the mounting location M2 of the backplane 20 is defined by baseconnectors 30 b 1,30 b 2 of interlocked base components 12 c 2. Theconnectors 60 b 1,60 b 2 of removable module 14 are adapted to mate withthe base connectors 30 b 1,30 b 2, respectively, so that module spansthe base connectors 30 b 1,30 b 2. Of course, the electrical conductors32 d of each base component 12 c 2 interconnect each of the baseconnectors 30 b 1,30 b 2 of the mounting location M2 to the other baseconnector 30 b 2,30 b 1 on the same base component.

When a removable module 14 is operatively mated to the backplane 20 asshown in FIG. 1, it is releasably interlocked to one of the basecomponents 12 c to prevent unintended separation of the module 14 fromthe backplane 20 by gravity, vibration, impact, vandalism, cablestresses and/or other external forces. FIGS. 2, 4 and 5 illustrate thateach intermediate base component 12 c 2 and the end base component 12 c3 comprises a coupling device 70 adapted to receive and retain a portionof a removable module 14 to connect the module to the base component 12c 2,12 c 3 to prevent unintended disconnection. FIGS. 7, 8 and 10clearly show that each module 14 comprises at least one and, preferably,at least two coupling projections such as spaced-apart hooks 82 a,82 bthat project outwardly from an inner surface 14 s thereof (the innersurface 14 s is defined as the surface of module 14 that contacts and/oris located adjacent the backplane 20 when the module 14 is mated to thebackplane). These first and second hooks 82 a,82 b are received intofirst and second slots 72 a,72 b (FIGS. 4,5) of the base componenthousing 32,34 and are retained by the coupling device 70 when the module14 is operatively connected to the backplane 20.

The structure and operation of the coupling device 70 and use of same tooperably couple a module 14 to the backplane 20 is explained furtherwith reference to FIGS. 12-16B, using an intermediate base component 12c 2 as an example. Those of ordinary skill in the art will recognizethat the coupling device 70 of an end base module 12 c 3 is structuredand functions identically. In FIG. 12, portions of the housing 32 arebroken away to reveal the coupling device 70. The coupling device 70comprises a lock member 74 that is slidably connected to the housing 32and adapted for reciprocating sliding movement between a first or“locked” position (FIGS. 12,16A) and a second or “release” position(FIG. 16B). The lock member 74 is preferably spring-biased into thefirst position.

FIG. 15 shows the lock member 74 by itself. In the illustratedembodiment, the lock member comprises a one-piece molded polymericconstruction comprising first and second ends 74 a,74 b separated fromeach other by a spring portion 74 c. The spring-biasing can be suppliedby a separate spring or other resilient element but, in the illustratedembodiment, the biasing is provided by the spring portion 74 c that isdefined as a part of the one-piece molded plastic lock member. Onesuitable polymeric material for molding the lock member is acetal,although other materials are contemplated and can be used. It is notintended that the development be limited to a one-piece molded polymericlock member, and the lock member can be defined from other materialsand/or fabricated from multiple pieces, and the term “member” as usedherein is not intended to be limited to a one-piece structure.

In the example shown herein, the spring portion 74 c comprises a frame74 d that defines an open space 74 e. At least one and, preferably, aplurallity of fingers 74 f project from the frame 74 d into the spaceand terminate in free distal ends comprising feet 74 g defined in theform of a post or other structure. With reference now to FIGS. 12 and13, the feet 74 g are engaged with bosses 74 i or other portions of thebody 32 of the base component 12 c so as to be restrained againstsliding movement with other portions of the lock member 74. Except forthe feet 74 g, the lock member 74 is slidably movable relative to thebody 32 of the base component 12 c between the first and secondpositions as indicated by the arrow 74 j, by exertion of force on theactuator portion 74 k of the lock member that projects outwardly awayfrom the housing 32. Thus, when the actuator 74 k is pulled outwardlyaway from the housing (FIG. 16B), the lock member 74 slides from itsnormal first position to its second “release” position, while thefingers 74 f resiliently deflect owing to the immovable engagement ofthe feet 74 g with the body 32 of the base component 12 c. Upon releaseof the actuator 74 k, the natural resilience of the fingers 74 f returnsthem to their original shape or “home” position as shown in FIGS. 12 and13 so as to move the lock member 74 back to its first “locked” position.

The lock member 74 comprises first and second latch portions 74 p 1,74 p2 that are conformed and dimensioned and otherwise adapted to receiveand retain the respective first and second hooks or other projections 82a,82 b of the module 14. The first and second latch portions 74 p 1,74 p2 are located respectively in the slots 72 a,72 b of the base componenthousings 32,34.

FIG. 14 shows a module 14 operatively mated to the backplane 20 in amounting location M1-M4, with the coupling projections 82 a,82 b thereofmated with and retained by the first and second latch portions 74 p 1,74p 2, respectively. The first and second latch portions are adapted tomate with the first and second hooks 82 a,82 b and thus comprisehook-like structures oriented oppositely relative to the hooks 82 a,82 bof the modules 14. The first and second latch portions 74 p 1,74 p 2 areeach defined with a sloped outer surface 76 k 1,76 k 2 oriented andlocated so that, during installation of a module 14 to the backplane 20,the projections 82 a,82 b of the module engage the sloped surfaces 76 k1,76 k 2 and urge the lock member 74 out of its natural first positiontoward its second position until the module 14 is fully seated againstthe backplane 20, at which time the spring portion 74 c of the lockmember 74 biases the lock member back to its first position so that thelatch members 74 p 1,74 p 2 engage the hooks 82 a,82 b, respectively,with a snap-fit so that a user received tactile feedback of full andproper installation of the module 14 to the backplane 20.

As shown in FIG. 14, when a removable module 14 is fully operativelyseated against a component 12 c of the backplane 20, the first andsecond hooks 82 a,82 b thereof are engaged with the first and secondlatch members 74 p 1,74 p 2. The lock member 74 also functions as amodule ejector and, thus, comprises one or more ejection surfaces suchas the first and second ejection ramps 74 r 1,74 r 2 (see also FIGS.4,5) conformed and arranged to engage the first and second hooks 82 a,82b or another part of the module 14 when the lock member 74 is movedtoward and into its second operative position. In the illustratedembodiment, the module coupling hooks 82 a,82 b comprise respectiveejection surfaces 84 a,84 b (see FIGS. 10,14) that lie adjacent theejection ramps 74 r 1,74 r 2. It is preferred that the ejection surfaces84 a,84 b and ejection ramps 74 r 1,74 r 2 be conformed as smooth matingsloped ramp surfaces.

With reference now to FIG. 14 and also FIGS. 16A and 16B, when the lockmember is moved from its first or “locked” position (FIGS. 14,16A) toits second or “release” position (FIG. 16B), the latch portions 74 p1,74 p 2 disengage from hooks 82 a,82 b to allow for separation of themodule 14 from the backplane. At the same time, the first and secondramp surfaces 74 r 1,74 r 2 of the lock member 74 slidably bear againstthe ejection surfaces 84 a,84 b of the module 14 and displace the moduleoutwardly away from the backplane 20 to a position where it will befreely separable from the backplane (even if the lock member 74 is againreleased and allowed to return to its normal locked position before themodule is lifted away from the backplane). The actuator portion 74 k ofthe lock member 74 is preferably defined with a recess 74 s that isadapted to receive a screw-driver blade or other tool T as shown inFIGS. 16A and 16B to facilitate movement of the lock member 74 from itslocked position to its unlocked position as shown.

The device 10 comprises a seal associated with each mated pair of a baseconnector 30 b 1,30 b 2 with a module connector 60 b 1,60 b 2 tosealingly engage these connectors and prevent contamination of thecontacts 30 c,60 c. FIGS. 7, 8 and 11 illustrate one embodiment of aseal formed in accordance with the present development, wherein a seal90 is associated with each module connector 60 b 1,60 b 2. When themodule connectors 60 b 1,60 b 2 are female socket-type connectors asshown, the seal 90 is located within the socket of the connector asshown. In this manner, when a module 14 is removed from the backplane 20and replaced with a new module, the new module is supplied with a newseal 90.

The seal 90 is explained with reference to FIGS. 17A-17C. As noted, aseal 90 is associated with each connector 60 b 1,60 b 2 of each module14. FIG. 17A shows an inner housing 40 a of a module 14 and first andsecond seals 90 connected thereto (the male pin contacts 60 c are notshown). The seals 90 are recessed within first and second connectorsockets 60 d 1,60 d 2 of the housing 40 b.

The seals 90 are each preferable defined as a one-piece molded polymericconstruction using any suitable elastomeric or other resilient polymericmaterial (as shown the two seals 90 are also defined as a one-piececonstruction with each other and are interconnected by a web 90 w). Inone embodiment, each seal 90 is defined as a one-piece moldedconstruction from a thermoplastic elastomer (TPE) such as SANTOPRENE®brand TPE, but it is not intended that the development be limited tothis material. It is possible for the seals 90 to be molded or otherwiseconstructed separately from the inner housing member 40 a, and theninstalled into the connector sockets 60 d 1,60 d 2 so as to be retainedby a friction-fit, adhesive and/or other means. It is deemed preferable,however, to utilize a two-step injection molding process: (i) a firststep to mold the inner housing 40 a, including the sockets 60 d 1,60 d2; and, (ii) a second step to mold the seals 90 directly into thesockets 60 d 1,60 d 2. This method reduces labor costs and is believedto result in a better connection of the seal 90 to the housing 40 a.

FIGS. 17B and 17C are sectional views that show one embodiment for theseal 90 and connection of same to the socket 60 d 1 (the seal 90 isconnected to the socket 60 d 2 in a corresponding fashion). The socket60 d 1 comprises an inner transverse wall 60 e through which a pluralityof apertures 60 f are defined to allow for installation of contacts 60 csuch as the male pins shown in FIG. 11 and elsewhere. The peripheralwall 60 p of socket 60 d 1 is generally cylindrical, and the seal 90comprises a correspondingly generally cylindrical peripheral wallportion 90 a that is closely conformed to the socket 60 d 1. The seal 90also comprises an annular inner wall 90 b arranged transverse to thecylindrical portion 90 a and abutted with the inner wall 60 e of socket60 d 1. The annular inner wall 90 b of seal 90 defines a central opening90 c that is aligned with the portion of the inner wall 60 e in whichthe apertures 60 f are defined to ensure that the seal 90 does notobstruct the apertures 60 f. The result of this structure is that theseal 90 has a generally L-shaped cross-section. If desired, the innerwall 90 b of seal can completely cover the inner wall 60 e of the socketand include apertures defined therein that are registered with theapertures 60 f of the socket inner wall 60 e. The outer end 90 d of seal90 preferably diverges moving out of the socket 60 d 1 to facilitateinsertion of a base connector 30 b 1,30 b 2.

The inner wall 60 e of the socket 60 d 1 also defines flow passages 60 gand, during the two-step molding operation, the material from which theseal is defined flows through these passages 60 g and then cures, withthe result being that the seal 90 is mechanically interlocked with thesocket 60 d 1 and anchored therein. Depending upon the particularmaterials from which the seal 90 and housing 40 a are molded, the seal90 can also be adhered to the socket 60 d and/or chemically bondedthereto as a result of the two-step molding operation.

The seal 90 comprises at least one and preferably at least two sealingelements that provide two different, transverse sealing dynamics. Asshown, the seal comprises a radial sealing element for sealinglyengaging radially or laterally adjacent surfaces and an axial(compressive) sealing element for sealingly engaging axially adjacentsurfaces.

The radial sealing element comprises at least one continuous radial lip92 that projects radially inward from the peripheral wall portion 90 atoward a central region of the socket 60 d 1. The one or more radiallips 92 are adapted to abut and sealingly engage the outer cylindricalor conical surfaces 36 b 1,36 b 2 (FIG. 2) of an associated baseconnector 30 b 1,30 b 2 inserted in the socket 60 d 1. If the associatedbase connector 30 b 1,30 b 2 is frusto-conical as described above, ithas been found to facilitate insertion and removal of the base connector30 b 1,30 b 2 relative to the socket 60 d 1 without compromising theeffectiveness of the radial sealing element 92.

The axial sealing element comprises at least one continuous axial lip 94that projects axially outward from the inner wall 90 b of the seal 90into the socket 60 d 1 toward the entrance 60 h of the socket. The oneor more the axial lips 94 are adapted to abut and sealingly engage thetransverse end wall 38 a,38 b(FIG. 2) of an associated connector 30 b1,30 b 2 inserted into the socket 60 d 1.

The combined radial and axial sealing has been found to be highlyeffective. The effectiveness of the radial and axial sealing elementsare enhanced owing to the use-of the coupler 70 for coupling theremovable modules 14 to the backplane 20 to ensure good and continuousengagement of the radial seal element 92 with connector surfaces 36 b1,36 b 2 and the axial seal element 94 with connector surfaces 38 b 1,38b 2, respectively. Furthermore, the module ejection function of thecoupler 70 that displaces the module 14 away from the backplane 20 asdescribed above helps to overcome the sealing engagement between themodule 14 and the backplane 20 established by seal 90 that can otherwisehinder separation of a module 14 from backplane 20.

FIGS. 18A,18B illustrate an alternative embodiment where a seal 190 isconnected to a base connector 30 b 1 instead of being located in asocket 60 d 1,60 d 2 of module 14 (the same arrangement can be appliedto a base connector 30 b 2). The seal 190 is similar to the seal 90 inthat it comprises a first portion 190 a that is closely conformed to andcovers at least part of the outer surface 36 b 1 of the connector. Theseal 190 also comprises an annular outer wall 190 b arranged transverseto the first portion 190 a and abutted with the outer transverse wall 38b 1 of the connector 30 b 1. The annular outer wall 190 b of seal 190defines a central opening 190 c that is aligned with the portion of theouter transverse wall 38 b 1 in which the apertures 39 are defined toensure that the seal 190 does not obstruct the apertures 39. The resultof this structure is that the seal 190 has a generally L-shapedcross-section. If desired, the inner wall 190 b of seal can completelycover the transverse wall 38 b 1 of the connector 30 b 1 and includeapertures defined therein that are registered with the apertures 39.

The seal 190 comprises at least one and preferably at least two sealingelements that act in transverse directions relative to each other. Asshown, the seal comprises a radial (lateral) sealing element and anaxial (compressive) sealing element.

The radial sealing element comprises at least one continuous radial lip192 that projects radially outward from the seal first portion 190 a.The one or more radial lips 192 are adapted to abut and sealingly engagean inner surface of the socket 60 d 1 in which the base connector 30 b 1is inserted.

The axial sealing element comprises at least one continuous axial lip194 that projects axially outward from the outer wall 190 b of the seal190. The one or more axial lips 194 are adapted to abut and sealinglyengage the inner wall 60 e (FIG. 2) of socket 60 d 1 when the baseconnector 30 b 1 is inserted into the socket.

FIGS. 19A and 19B illustrate an alternative device 210 that is identicalin all respects to the device 10, except as otherwise shown and/ordescribed. Like components relative to the device 10 are identified withlike reference numerals that are 200 greater than those used inconnection with the device 10. The device 210 comprises a backplane 220that is identical to the backplane 20 except that the base connectors230 b 1,230 b 2 are female socket connectors comprising male pincontacts 230 c. Modules 214 are adapted for releasable connection to thebackplane 220 as described above for the modules 14, except that themodule connectors 260 b 1,260 b 2 are male plug connectors includingfemale contacts 260 c. The device 210 comprises either seals 90 locatedin the sockets 230 b 1,230 b 2 or seals 190 connected to the plugconnectors 260 b 1,260 b 2.

The invention has been described with reference to preferredembodiments. Modifications and alterations will occur to those ofordinary skill in the art, and it is intended that the claims beconstrued literally and/or according to the doctrine or equivalents toencompass all such modifications and alterations.

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 26. An input/output module comprising: a housingcontaining input/output electronic circuitry for adapted for industrialautomation input/output functions; a plurality of input/outputelectrical connectors operably connected to the input/output circuitryand projecting outwardly from the housing; first and second electricalmodule connectors adapted to mate respectively with first and secondbase connectors of an associated backplane; at least one couplingprojection that projects outwardly from the housing and conformed tomate with and be selectively retained by a coupling device of theassociated backplane.
 27. The input/output module as set forth in claim26, wherein said housing comprises: an inner housing and an outerhousing inter-fitted with each other to define an interior space inwhich said input/output electronic circuitry is contained.
 28. Theinput/output module as set forth in claim 27, wherein said plurality ofelectrical connectors project through and outward from said outerhousing and wherein said plurality of electrical connectors and saidinput/output electronic circuitry are potted in said outer housing., 29.The input/output module as set forth in claim 27, wherein the innerhousing is nested within the outer housing, one of the inner and outerhousings comprising a plurality of tabs and the outer of said inner andouter housings comprising a plurality of recesses, wherein saidplurality of tabs are respectively received in said plurality ofrecesses with a snap-fit.
 30. The input/output module as set forth inclaim 29, wherein the inner housing comprises a continuous wall and saidouter housing defines a continuous groove in which said continuous wallis received.
 31. The input/output module as set forth in claim 30,wherein at least one of a gasket, adhesive and sealant is located insaid continuous groove between said outer housing and said continuouswall of said inner housing.
 32. The input/output module as set forth inclaim 27, wherein said inner and outer housings are each defined as aone-piece molded polymeric construction.
 33. The input/output module asset forth in claim 32, wherein said inner and outer housings are eachdefined as a one-piece molded polymeric construction comprisingglass-filled polyester.
 34. The input/output module as set forth inclaim 26, wherein said first and second electrical module connectors aredefined by respective first and second female socket connectors.
 35. Theinput/output module as set forth in claim 34, further comprising firstand second seals located respectively in said first and second femalesocket connectors.
 36. The input/output module as set forth in claim 35,wherein said first and second seals are defined from a resilientpolymeric material.
 37. The input/output module as set forth in claim36, wherein said first and second seals are defined by a one-piecemolded polymeric constructions and are connected to each other by apolymeric web that is extends between said first and second femalesocket connectors.
 38. The input/output module as set forth in claim 35,wherein said first and second female socket connectors are defined insaid inner housing, and wherein said first and second seals aremechanically interlocked with said inner housing where portions of saidfirst and second seals are molded into flow passages defined by saidinner housing.
 39. The input/output module as set forth in claim 35,wherein said first and second seals are each defined by a cylindricalperipheral wall and an end wall connected to and arranged transverse tosaid cylindrical peripheral wall.
 40. The input/output module as setforth in claim 39, wherein said first and second seals each comprise: aradial sealing lip that projects radially inward from said cylindricalperipheral wall; and, an axial sealing lip that projects axially outwardfrom said end wall.
 41. The input/output module as set forth in claim26, wherein said at least one coupling projection comprises a firsthook-shaped projection.
 42. The input/output module as set forth inclaim 41, wherein said at least one coupling projection comprises firstand second spaced-apart hook-shaped projections.
 43. The input/outputmodule as set forth in claim 42, wherein said first and secondhook-shaped projections are connected to and defined as a one-piececonstruction with the inner housing.
 44. The input/output module as setforth in claim 42, wherein said first and second hook-shaped projectionscomprises respective ejection surfaces adapted to be engaged by thecoupling device of the associated backplane when the coupling device islocated in a release position.
 45. An electrical module adapted to matewith first and second base connectors of an associated backplane, saidmodule comprising: a housing; first and second module connector socketsadapted to mate respectively with the first and second base connectorsof the associated backplane; and, first and second coupling hooks thatprojects outwardly from the housing and that are adapted to mate with acoupling device of the associated backplane.